Method of making outlet boxes



March 6, 1951 F. J. KENNEDY 2,544,266

METHOD OF MAKING OUTLET BOXES Original Filed June l, 1948 2 Sheets-Sheet 1 E La Www/27 March 6, 1951 F. J. KENNEDY METHOD oF MAKING OUTLET BoxEs -2 Sheets-Shee'I 2 Original Filed June 1, 1948 0 www 72 @7% bun/ENTv a Haq Jffm Il l III riillllll. iii!!! llllll Illlllio Patented Mar. 6, 1951 UNITED STATES PATENT O FF ICE METHOD `OF MAKING OUTLET BOXES `Frank J. Kennedy, Mount Lebanon, Pa., -assignor to National -Electric Products Corporation, Pittsburgh, VPa., a vcorporation of Delaware VDivided and this application August 15, 194,9, SeriallNo. 110,431

:3 Claims. l This invention relates to a method of making electrical outlet and junction boxes, hereinafter designated simply as `outlet boxes; andthe application herein is a division of my-co-pending application Serial No. 30,221, -led June l, V1948.

One object of the invention is 4to provide a fabricated outlet box which is firmly :integrated and sturdy in its structure, and particularly in the tightness yand lsecurity with which the bottom of the outlet box is Aintegrated With the other outlet box structure.

Another object of the invention is to provide a method of makingfabrica-ted outletboxes -possessing the vproperties above noted which are integrated Wholly by means of the substance oit-their primary structural parts, without Welding or soldering and without the `use of added connecting parts or pieces.

Another object of the invention is tofproduce outlet boxes of such simple 4 structure -byaimethod so simple Yand direct lthat the outlet box is expeditiously and economically manufactured and that vWaste of metal in -sc-rap is minimized.

A still Vfurther object of Vthe invention is Atofprovide outlet boxes having the labove noted `properties which also havesharply dened'con't-ours and the Vwall structure of `which presents extended plane surfaces connected on relatively short radii.

Electrical outlet boxes which -are-used-in great numbers, are 'subjected ito rough handling in installation and are subjected when installed -to jars Vand Avibration Which'may be of great severity. The bottom Wall of an voutlet box -li-es against a building Wall or other structure 'directlyto mount the outlet -box andthe bounding walls'of th-ecutlet box support at their knockouts 'electrical devices of various sorts, so that there are exerted on a mounted outlet box forces 'tending `to separate 01 loosen the connection Ebetween the bottom ywall and other 'walls of the outlet box. It is desirable that the bottom wall of the outlet box should elie dead 'against la 'plane lsurface on which the outlet `box is mounted, Without Stend- 2 of the box is nrelatively loose and insecure, or is eiected by welding, 4as is Yalso the integration of the lbounding wall structure, with consequent increase in ltime and equipment necessarily employed in making the outlet box.

In Ypreferred practiceof my :method rthe product comprises side walls -and Yend walls bent yfrom a single llengtl-iof vpreformed metal strip the endsof which :are luni-ted by an vinter-locked, Weldless, joint. Retainer feet for engagement by afseparat-ely Yformed bottom Wall or v'plate are punched out of the rsubstanoeof the side and end walls lin spaced relation with the adjacent edges thereof. The VWalls are scored 'with -a groove parallel to the Ibottom edges Yof Lthe Walls and spaced yto form -a 'line of prepared exu-re spaced by the thickness of lthe 'bottom vWall -from -a line dened by the plurality of retainer feet. The bottom Wall is clinched `against the retainer -feet by cli-nching flanges which are bent over 4at the score line and brought into clinching engagement with a bottom wall forced against'the retainer feet.

The method of making my outlet box involves progressively forming the side and end Walls by unwinding strip of ,suitable Width from a coil and scoring 'it parallel to one edge While forming notchesvspaced alongsaid edge. I stamp out the bottom `retainer feet and the customary knockouts 'fin successive stages, sever the proper length Of strip alOD-g a dovetail shear line, then bend the length to bring its `ends together and assemble the separatedly formed bottom plae with the side and end walls 'thus produced.

A complete .understanding of the invention may be obtained from the following detailed description and explanation which refer to the .accomf panying drawings `illustrating .a rpreferred embodiment of the lpludllct `and ipractice of the method. In thefdrawings,

Fig. I-is -a side elevation of -the strip `of Which the bounding wall structure of the boxes yis -made as vit is unwound from -a1coi1, Ashowing ,the successive stages of 'the formation kthereof into a blank comprising the elements of a continuous outlet box wall including Ysides .and Iends.

Fig. II 'is a -plan view ,corresponding zto Fig. I but omitting .the showing of knockouts lbecause of the inherent limitations of .illustration .in this dimension.

Eig. IlEI l is.a plan view of thesideand end ,wall structure of :the :outlet .box l:following ,the `bending and integration of :a .prepared .piece :to provid the ambient cwallstructurefof `the-box.

Fig. :IY is fa longitudinal .section through fthe 3 box taken in inverted position of the box in the plane of section line IV-IV of Fig. III.

Fig. V is a view similar to Fig. IV showing marginal bottom portions, or Clinching anges, of the side and end walls partly bent over marginal regions of the bottom wall or plate of the outlet box.

Fig. VI is a view similar to Figs. IV and V showing the marginal portions, or Clinching flanges, of the side and end Walls in bottom-Clinching position.

Fig. VII is a sectional detail View on an enlarged scale, taken in the plane of the section line VII- VII of Fig. I, illustrating the structure of a piece prepared for the bounding wall structure of the box before its formation and integration into such structure.

Fig. VIlI is a fragmentary sectional view taken in correspondence to the section and scale of F.g. VII but illustrating the stage in the integration of the outlet box shown in Fig. V.

Fig. IX is a view similar to Fig. VIII but illustrating on an enlarged scale the completion of the operation of integrating the outlet box as shown in Fig. VI.

Referring initially to Figs. I and II of the drawings, metal strip I is unwound progressively and with a minimum of spaced interruptions from a coil 2 mounted in any suitable manner. As unwound, the strip is passed step-by-step through the appropriate instrumentalities of a multislide press which act progressively on successively presented lengths oi the strip.

In the region A closest to the coil, a continuous groove 3 is impressed parallel to one edge l (later to be incorporated in the bottom structure of the outlet box) and spaced substantially from the edge. Also V-notches 5 are cut out from the marginal region lying between edge ll and groote 3. At the opposite edge of the strip 5 (late: to be the upper edge of the outlet box) marginal material is cut away in regions indicated at 'I to leave spaced ears or lugs In the next operation a piece of strip I corresponding in dimensions to the length A, the action on which has been described, is dened. In the second action of the press holes 9 are punched in lugs Also the length I5 of the strip, which may be now considered as a prospective piece B, is dened by transverse lnes oi severance II. In this action knockouts I2 are pressed from regions of thepiece which ultlmate- 1y are to serve as the longer or side walls of the outlet box, and similar knockouts I3 are pressed in the regions which are ultimately to form the shorter or end walls of the outlet box. The groove 3 is deepened and a line of retainer ieet Id is defined and the retainer feet are partially pressed from the substance of the strip to extend on the same side of the strip as the groove 3 in a lne parallel to the groove and spaced inwardly from it a distance which is regulated by. the desired thickness of the bottom plate for the outlet box which is subsequently to be applied. i

In the next action the length of strip is formed into a knocko piece C... In that piece the lines of severance I'I, which are of dovetail formation and which had been slightly impressed in the strip, are made deeper and as shown one of those lines of severance stands as a free dovetail edge because of the succeeding action in which a piece is knocked off and formed. It should be noted that in each piece the dovetail ends formed at the lines of severance match, inasmuch as the dovetail tangs and notches at the leading end of each piece have been formed with complementary notches and tangs at the trailing end of the next preceding piece. In piece C retainer feet I4 are fully formed, being severed along a line adjacent groove 3 and deected into a position and form in which a portion Ilia of each or" the feet stands parallel to the body of the strip and presents a free edge I4b substantially perpendicular to the plane of the strip.

In the above noted successive actions the three lengths of strip A, B and C are acted on simultaneously as the strip is advanced step-by-step and for this reason the three lengths A, B and C are shown in Fig. I as simultaneously existing, the lengths A and B being shown in fragmentary manner and the nal or knock-off piece C being completely shown. There is also a fourth length simultaneously acted on in the press, such length which is a piece similar to piece C, has been severed and formed into the bounding wall structure of the outlet box. Relating this final action of the press to piece C, that piece next is knocked off and is formed by dies into the bounding wall structure of the outlet box, as shown in Figs. III and IV. In this action knockouts I2 and I3 which have projected from the plane of the strip are forced back into line with it, and lugs 8 are bent over to a position at right angles with the plane of the walls from the edges oi' which they extend. The matching dovetails at the opposite ends of the piece are brought together and are forced into interlocking relation with each other to form an interlocked joint. The marginal regions of the strip lying between edge 4 and the score line are shaped with the remainder of the wall portions with which they are coextensive Ato provide a plurality of upstanding flanges separated by the notches 5.

Referring particularly to Figs. IV, V and VI of the drawings which illustrate the formation of the outlet box, Fig. IV shows the bounding wall structure of the outlet box standing in inverted position with score lines 3 and retainer feet I4 extended completely around the box and with the interval between the upper edges of the retainer feet and the score line clearly dened. Clinching flanges lying beyond the score line remain in opstanding position continuous with the plane of the walls. In this position and relation of its elements the partially manufactured outlet box is placed in a suitable press and bottom plate I5 is applied to rest on retainer feet I4.

In Fig. V bottom plate I5 is shown in a position occupying the space between the upper edges of the retainer feet and the groove. Clinching flanges IG have been bent over by the press to a position in which they stand at an angle of 45 or slightly more with the planes of the bounding walls, marginally to overlie the bottom plate.

In Fig. VI the outlet box is shown in completed form as-effected in the next pressing operation. In this final stage bottom plate I5 is tightly and securely engaged with the side walls solely by the Clinching effect of anges I6 which are forced downwardly into full Clinching position on marginal regions of the bottom plate against the solid backing provided by the plurality of upstanding retainer feet I4. It will be understood that in bringing the flanges I 6, which extend along each of the reaches forming the side and end portions of the bounding wall, V-notches 5 give the clearance necessary to allow the adjacent without interference.

It'should be appreciated that the integration of suming a considerable amount of time in handling and in making the weld adds a large. item of cost to the manufacture of the. fabricated` box. There is substantial scrap` loss, by reason of imperfect welding and if` the boxY be dropped or forcefully struck there is danger of breaking the weld. The expedient. of using:` lugs, such as the attachment lugs 8. of the applicants outlet. box, also is unsatisfactory.. While;A those lugs are suitable for the attachment. of a. cover, or thelike, an attempt to secure a bottom plate or wall in position by engaging it between alternately positioned lugs has proven inadequate, because it permits play between the bottom plate of the outlet box and its bounding walls and progressive loosening with handling and under jars or vibration. The attachment of the bottom plate by screws or rivets also is unsatisfactory.

In engaging the bottom plate of the outlet box to the bounding walls by a pressed engagement the problem thus is to effect a clinching which is sufficiently secure and tight to hold the bottom plate permanently and immovably in position. In my outlet box such clinched engagement is obtained by providing a firm resistant backing at one side of the plate against which backing the pressing operation can be performed, and to bring the engaging flanges which secure the bottom plate against such backing into full clinching position. The parts by which that effect is obtained are shown in detail in Figs. VII, VIII and IX of the drawings.

Thus considering Fig. VII it will be seen that foot II presents its edge Illb in a plane at right angles to the plane of the strip and that it is initially severed along that edge and deflected away from the plane of the wall toward what is to be the cavity of the outlet box, to provide a seating surface in a region which is removed from the nearest edge of the strip. Foot I4 thus is not of the nature of an ear or lug formed at the edge of the wall, but the foot has a rigidity attendant upon its location and the fact that it has a substantial reach Ilia extended parallel to the wall. By using a plurality of feet lli of relatively small size a rigid backing which is capable of sustaining great pressure is provided as a clinching seat for bottom plate I5. Further referring to Fig. VII, it will be seen that groove 3 is spaced from both the edges I 4b of feet I4 and from the extreme edge ll of the strip.

Fig. VIII shows the condition preparatory to the clinching action. In this figure of the drawings bottom plate I5 rests on the edges Iiib of the fee-t and against the inner surface of the bottom wall to occupy space between the edges Ilib and groove 3. Clinching flanges IES standing outwardly of groove 3 and separated by V- notches 5 have uninterrupted reaches extending each along one of the four bounding walls of the outlet box.

Fig. IX shows bottom plate I5 securely clinched against retainer feet I4 by folding clinching anges I6 at grooves 3 and pressing them forcefully against marginal regions of bottom plate I5, which in turn is forced firmly against the plurality of retainer feet I4. In this action, which preferably is effected in two stages as is illustrated in Figs. V and VI of the drawings,

.groove 3 performs: an important function. This is to cause the clinching flanges to be folded cleanly and sharplyagainst. the adjacent edges of the. bottom'plate as well as to faciliate the bending., Thus the edges of bottom plate I5 being received in the space provided by groove 3, a. clean positive. clinching joint is made, securely vand immovably to integrate the bottom plate with the boimding walls of the outlet box..

As explained, the elements shown and de. scribed and illustrated in detail in Figs.. VII, VIII and IX.. result in the formation of av firmly integrated. outlet. box which possesses allA the advantageous. features of a fabricated outlet box in conjunction with all the advantageous features of a deep-drawn outlet. box. Thus` the integration of. the boxi is such that the bottom is held. securely and immovably with the bounding walls against rough handling and the jars and vibrations of service. The outlet box has a bottom structure which rests flat and dead on a plane surface and the radii along the edges of the bottom and at the junction of the side and end walls of the box are so short as to give the outlet box a sharply defined contour and provide a maximum of space within the box. rThe outlet box is manufactured by a method which is both rapid and inexpensive inasmuch as it avoids the relatively unsatisfactory modes of integrating the bottom of the outlet box with the bounding walls which previously have been practiced. The box as a whole is weldless, the entire integration being effected by the substance of its primary structural parts without welding or soldering and without the use of added connecting parts or pieces. The scrap loss is very low, both in minimizing the metal which is cut away in preparing a structural piece and in forming it into the bounding wall structure of the outlet box and in the scrapping of completed or partially completed outlet boxes because of defects. In the later instance great advantage is presented over the manufacture of outlet boxes by a deep-drawing operation in which the scrap loss is high because of the high proportion of defective boxes produced by that operation.

Although I have illustrated and described only a preferred embodiment and practice of the invention, it will be recognized that changes in the structural detail and procedure disclosed may be made without departing from the spirit of the invention or going beyond4 the scope of the appended claims.

I claim as my invention:

1. The method of making an electrical outlet box by scoring a groove adjacent and parallel to a longitudinal edge of piece of metal strip, cutting notches at intervals to extend from the edge of the said piece approximately to the said groove, displacing from the substance of the piece on a line parallel to the said groove and spaced therefrom away from the adjacent edge ofthe piece a plurality of retainer feet of small size and sturdy construction to provide a rigid pressure-sustaining backing, bending the said piece and interengaging the ends thereof to form the bounding wall structure of the outlet box, placing a separately formed bottom plate against said retainer feet within the space bounded by said wall structure substantially to ll the space between said groove and the adjacent surfaces of the said retainer feet, and integrating the said bottom plate with the said bounding wall structure by folding the portions of the said wall structure between notches at the line of said groove into clinching relation with a marginal region of the said bottom plate.

2. The method of making an electrical outlet box as dened in claim 1 which is further characterized by folding the clinching ilanges between notches of the bounding wall structure of the outlet box in two stages, rst into a position of inward inclination from the plane of that portion of the bounding Wall structure from which each of the said flanges projects and then into clinching relation with the said bottom plate and in opposition to the said retainer feet.

3. The method of making an electrical outlet box as defined in claim 1 which is further characterized by forming the ends of the said piece of strip as matching dovetail structures, and in bending the said piece into the form of the bounding wall structure bringing the said dovetail ends into interlocking engagement to integrate. the said bounding Wall structure by an interlocked joint.

FRANK J. KENNEDY.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PA'I'ENTS Number Name Date 1,723,753 Vance Aug. 6, 1929 1,999,818 McIntyre Apr. 30, 1935 2,058,671 Steenweg Nov. 3, 1936 2,123,842 Cox July 12, 1938 

